Method of manufacturing optical fiber cable covered with metal pipe, and apparatus for manufacturing this optical fiber cable

ABSTRACT

An apparatus for manufacturing an optical fiber cable covered with a metal pipe forms a metal pipe by abutting two sides of a metal strip to be pulled, introduces an optical fiber or an optical fiber bundle into the metal pipe, and seals the opening of the metal pipe by laser welding. A squeeze shoe is arranged immediately before a welding position. The inner circumferential surface of the squeeze shoe is brought into contact with the metal pipe, and the section of this inner circumferential surface conforms to the outer circumferential surface of the metal pipe. The squeeze shoe is vertically divided into halves. Since the squeeze shoe is provided immediately before the welding position, the opening of the metal pipe can have a predetermined width and be welded. The opening width is adjusted in accordance with at least one of a diameter, thickness and composition of the metal strip and in accordance with at least one of a welding rate, laser beam power and laser beam focus shift amount of the laser welder. Thus, thermal damage to the optical fiber can be reliably prevented, and defective welding caused by a spatter can be prevented, so that a long-time continuous operation is enabled. An elongated optical fiber cable covered with a metal pipe can be manufactured.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of manufacturing an opticalfiber cable covered with a metal pipe, and an apparatus formanufacturing this optical fiber cable.

2. Description of the Related Art

When a tension is applied to an optical fiber having a diameter of 250μm, although a breaking strength is as rather large as about 6 kg, theelongation is 3 to 6%. This elongation is considerably small as comparedto that of a conventional copper or aluminum cable. For this reason, atensile strength member must be provided to the optical fiber tomaintain a high optical fiber cable strength. When an optical fiber isdipped in water, its strength is sometimes degraded. Therefore, whenlaying an optical fiber cable underseas or underwater, an optical fibercable having a sheath structure obtained by covering an optical fiberwith a thin metal pipe must be employed to maintain a high layingtension and water resistance.

Conventionally, when such an optical fiber having a small diameter is tobe covered with a metal pipe, the optical fiber is inserted in a metalpipe having a gap in the longitudinal direction, and this gap is weldedby soldering. According to this method, however, heat generated duringwelding of the metal pipe is applied to the optical fiber through thegap for a comparatively long period of time, leading to thermal damageto the optical fiber.

Jpn. Pat. Appln. KOKAI Publication No. 64-35514 discloses an apparatusand method of continuously manufacturing an optical fiber covered with ametal pipe by welding the abutting portion of the metal pipe with afocused laser beam, so that thermal damage in the optical fiber isprevented. In this apparatus for manufacturing an optical fiber cablecovered with a metal pipe, a flat metal strip which is continuouslysupplied is formed into a metal pipe having a longitudinal gap at itstop portion. An introducing tube is inserted in the metal pipe throughthe gap in the metal pipe, and an optical fiber is inserted in the metalpipe through the introducing tube. After the gap of the metal pipe inwhich the optical fiber is introduced is closed, the metal pipe issupplied to a laser welding unit. The laser welding unit irradiates alaser beam having a focal point at a position outwardly remote from thesurface of the abutting portion while positioning the abutting portionat the top portion of the supplied metal pipe with a guide roller,thereby welding the abutting portion. In this manner, welding of theabutting portion is realized by shifting the focal point of the laserbeam from the abutting portion without protecting the optical fiber witha heat-shielding member. Subsequently, the outer diameter of the metalpipe incorporating the optical fiber is reduced to a predetermined size,and the metal pipe is wound on a capstan and continuously withdrawn fromthe capstan.

In withdrawal of the metal pipe, an inert gas is supplied to theintroducing tube. The optical fiber is transported into the metal pipewith the viscosity resistance of the inert gas. While the metal pipe isengaged with the capstan, the optical fiber is positioned on an outerside of the inner portion of the metal pipe by blowing the inert gas.Thus, when the metal pipe is set straight, the length of the opticalfiber becomes larger than that of the metal pipe, so that the opticalfiber flexes in the metal pipe, thereby preventing the optical fiberfrom causing a strain by the laying tension or the like.

Furthermore, when the metal pipe is damaged to form a hole, water canenter through the hole to degrade the optical fiber. In order to preventthis, a gel filler is injected into the metal pipe. More specifically,after the optical fiber is blown to the outer side within the metal pipewith the inert gas at the capstan, a filler is injected into the metalpipe through a filler introducing tube which is different from theintroducing tube that introduces the optical fiber.

However, in the conventional method of manufacturing an optical fibercable covered with a metal pipe, since the position of the introducingtube is not constant in welding the abutted portion of the metal pipe,the introducing tube is sometimes arranged close to the abutted portionof the metal pipe. In this case, heat generated by laser welding isapplied to the optical fiber to thermally damage it. For example, whenthe temperature in laser welding is measured while the optical fiber isclose to the abutted portion in this manner, the temperature near theoptical fiber is increased to at least about 600° C. Thus, a crystallitenucleus is formed in the optical fiber. As the crystallite nucleusgrows, it increases the scattering loss, leading to a disadvantage. Thisis a phenomenon called devitrification.

During welding, a spatter is generated. When the introducing tube isclose to the abutted portion, the spatter deposited on the introducingtube tends to contact the bead on the rear surface of the weldingportion. When the spatter contacts the rear surface of the weldingportion, the heat balance of the welding portion is disordered to causedefective connection. When formation of the rear bead portion thatgenerates the spatter is excessively suppressed in order to avoiddefective welding caused by the spatter, a non-welded portion isundesirably formed. Also, when the introducing tube is in contact withthe abutted portion, a phenomenon similar to defective welding caused bythe spatter occurs. Therefore, it is impossible in practice to perform along-time continuous manufacturing operation, i.e., to perform anoperation of manufacturing an elongated metal pipe-covered optical fibercable.

Furthermore, in laser welding, if the irradiating power intensity of thelaser beam is excessively high, the metal pipe is heated to atemperature equal to or higher than its boiling point, so that part ofthe metal pipe is evaporated or scattered to form a hole in theirradiated surface. In order to prevent this, conventionally, the focalpoint of the laser beam is not formed within the thickness of theabutted portion of the metal pipe but is formed above the metal pipe.When, however, the focal point is formed above the metal pipe, thesectional shape of the melt zone swells in its lower portion. Then, ashrinkage void or crack tends to be formed in the metal pipe, and theamount of spatter is increased.

From these situations, one of the present inventors previously proposeda method disclosed in U.S. Pat No. 5,241,153 and U.S. Ser. No.08/078,574 to solve the above problems. According to this proposal, thefocal point of the laser beam emerging from the laser irradiating meansis shifted by fixing the abutted portion of the metal pipe at apredetermined position slightly above or below the focal point of thelaser beam and/or the path line of the metal pipe, and the laser beam isirradiated in this state.

The present inventors noticed the fact that the optimum width of theopening formed in the abutted portion of the metal pipe differsdepending on other welding conditions (the welding rate, the power ofthe irradiated laser beam, and the focal shift amount of the laserbeam), and studied an apparatus for adjusting the opening width of theabutted portion of the metal pipe. In the process of the study to reachthe present invention, the present inventors considered adjusting theopening width of the metal pipe with known squeeze rolls. However, sincethe diameter of the metal pipe is too small, even if the metal pipe isheld by the known squeeze rolls, the held portion and the weldingportion are separated. As a result, the gap is gradually increased dueto the function of spring back of the metal pipe. Thus, it is difficultto appropriately adjust the opening width of the abutted portion at thewelding portion. More specifically, when the opening width is increased,welding becomes unstable, so that the welding rate must be decreased. Onthe contrary, when the opening width is excessively small, defectivewelding occurs. Thus, the welding rate cannot be increased in the samemanner as in a case wherein the opening portion is excessively widened.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an apparatus andmethod of manufacturing an optical fiber cable covered with a metalpipe, in which the welding rate can be increased.

It is another object of the present invention to provide an apparatusand method of manufacturing an optical fiber cable covered with a metalpipe, which can perform optimum welding in accordance with the metalpipe and the welding conditions of the metal pipe.

It is still another object of the present invention to provide anapparatus and method of manufacturing an optical fiber cable coveredwith a metal pipe, which enable a long-time continuous operation byreliably preventing thermal damage to the optical fiber and bypreventing defective welding caused by a spatter, so that an elongatedoptical fiber cable covered with a metal pipe can be manufactured.

It is still another object of the present invention to provide anapparatus and method of manufacturing an optical fiber cable coveredwith a metal pipe, which can perform welding reliably.

According to the present invention, there is provided an apparatus formanufacturing an optical fiber cable covered with a metal pipe,comprising: forming means for forming a metal strip into a metal pipehaving a slit type opening by abutting two sides of the metal strip;opening width adjusting means, arranged on a stage after the formingmeans, for adjusting a width of the opening to a predetermined size;welding means, having means for irradiating a laser beam to the openinghaving the adjusted width, for forming a sealed metal pipe by weldingthe opening; and optical fiber introducing means for introducing anoptical fiber or an optical fiber bundle into the sealed metal pipe.

The opening width adjusting means comprises squeeze shoe means forpassing the metal pipe along an inner circumferential surface thereof,the inner circumferential surface of the squeeze shoe means having ashape conforming to an outer circumferential surface of the metal pipe,urging means for urging the squeeze shoe means toward the metal pipe,and urging force adjusting means for adjusting an urging force of theurging means. The squeeze shoe is preferably divided vertically intohalves and arranged immediately before a welding portion by 3 mm to 15mm. The apparatus preferably comprises positioning means between theforming means and the opening width adjusting means, to be located aboveor below a focal point of a laser beam and/or a path line of the metalpipe by a desired distance. The apparatus preferably comprises tube-likeoptical fiber protecting means, inserted in the metal pipe, forintroducing the optical fiber or the optical fiber bundle into the metalpipe and protecting the optical fiber or the optical fiber bundle fromwelding heat, and means for elastically pressing the optical fiberprotecting means against an inner wall of the metal pipe on a sideopposite to a surface thereof irradiated with a laser beam.

According to the present invention, there is also provided a method ofmanufacturing an optical fiber cable covered with a metal pipe,comprising: the forming step of forming a metal strip into a metal pipehaving a slit type opening by abutting two sides of the metal strip; theopening width adjusting step of adjusting an opening width of theopening to a predetermined size; welding step of forming a sealed metalpipe by welding the opening, the welding step having a substep ofirradiating a laser beam to the opening; and the optical fiberintroducing step of introducing an optical fiber or an optical fiberbundle into the sealed metal pipe. The welding step preferably comprisesthe step of irradiating a laser beam to the abutted portion of the metalpipe with a desired focal shift amount. The laser beam forms a focalpoint inside the abutted portion. The welding step preferably comprisesthe step of setting the maximum focal shift amount of the laser beambased on the minimum rear bead width, the step of setting the minimumfocal shift amount based on the maximum rear bead width, the step ofsetting a welding rate in accordance with the preset maximum and minimumfocal shift amounts, and the step of irradiating the laser beam within arange of the maximum and minimum focal shift amounts. The methodpreferably comprises the step of inserting tube-like optical fiberprotecting means at least to a portion in the metal pipe where theoptical fiber protecting means receives welding heat, the step ofintroducing the optical fiber of the optical fiber bundle into the metalpipe through the optical fiber protecting means, and the step ofprotecting the optical fiber or the optical fiber bundle from thewelding heat during welding the metal pipe.

Additional objects and advantages of the invention will be set forth inthe description which follows, and in part will be obvious from thedescription, or may learned by practice of the invention. The objectsand advantages of the invention may be realized and obtained by means ofthe instrumentalities and combinations particularly pointed out in theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate a presently preferred embodimentof the invention and, together with the general description given aboveand the detailed description of the preferred embodiment given below,serve to explain the principles of the invention.

FIG. 1 is a view showing the entire arrangement of an embodiment of thepresent invention;

FIGS. 2A and 2B are sectional views respectively showing a metal pipe ina forming step;

FIGS. 3A, 3B, and 3C are side views showing forming roller pairs of thesecond assembling body, respectively;

FIG. 4 is a view showing the arrangement of an optical fiber introducingmeans;

FIG. 5 is a view showing the arrangement of a laser welding means;

FIG. 6A is a sectional view showing guide shoes, and FIG. 6B is asectional view showing squeeze shoes;

FIG. 7A is a front view showing a tension changing means and a tensionadjusting means, and FIG. 7B is a plan view of the same;

FIG. 8 is an explanatory view showing the abutting portion of a metalpipe;

FIG. 9 is a graph showing the relationship between the tube outerdiameter and the rear bead width;

FIG. 10 is a graph showing the relationship between the tube wallthickness and the rear bead width;

FIG. 11 is a graph showing the relationship between the welding rate andthe focus shift amount;

FIG. 12 is a graph showing the relationship between the welding rate andthe focus shift amount;

FIG. 13 is a graph showing the relationship between the welding rate andthe focus shift amount;

FIGS. 14 to 17 are graphs each showing an extra length controloperation;

FIG. 18 is a partial view showing another arrangement of the opticalfiber introducing means;

FIG. 19 is a partial view showing the arrangement of another embodiment;

FIG. 20 is an explanatory view of a plate spring mechanism;

FIG. 21 is an explanatory view showing a state wherein the metal pipe ispositioned upward;

FIG. 22A is an explanatory view showing the bent states of anintroducing tube, and FIG. 22B is an explanatory view showing anintroducing tube positioning mechanism;

FIG. 23 is an explanatory view showing the positioning state of themetal pipe at a welding position;

FIG. 24 is an enlarged view of a metal pipe length adjusting means; and

FIG. 25 is a graph showing the relationship between the distance, thatinfluences the weldability, of the squeeze shoe from the weldingposition and the welding rate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows the entire arrangement of an apparatus for manufacturing anoptical fiber cable covered with a metal pipe according to an embodimentof the present invention. This apparatus has a tension adjusting means14 for adjusting the tension of a metal strip 1. A forming means 2 forforming the metal strip 1 into a metal pipe by abutting the two sides ofthe metal strip 1 is provided on the output stage of the tensionadjusting means 14. The forming means 2 has a first assembling body 3and a second assembling body 4. This apparatus also has a tensionadjusting means 15 for adjusting the tension of an optical fiber 5. Anoptical fiber introducing means 6 for introducing the optical fiber 5into the formed metal pipe is provided, on the output stage of thetension adjusting means 15, between the first and second assemblingbodies 3 and 4. A laser welding mechanism 7 is provided on the outputstage of the forming means 2. A measuring section 8 and a diameterreducing means 9 are continuously provided on the output stage of thelaser welding mechanism 7. A traction means is provided on the outputstage of the diameter reducing means 9. The traction means has a tensionchanging means 11 and a tension adjusting means 13. A metal pipe lengthadjusting means 130 is provided on the output stage of the tractionmeans. The metal pipe length adjusting means 130 adjusts the length ofthe metal pipe by reducing the diameter of the metal pipe. A cabletake-up machine 10 is arranged on the output stage of the metal pipelength adjusting means 130.

The tension changing means 11, the tension adjusting means 13, the metalstrip tension adjusting means 14, the optical fiber tension adjustingmeans 15, and the metal pipe length adjusting means 130 constitute anextra length control means for adjusting the length of the optical fiberrelative to the metal pipe, i.e., for adjusting the extra length.

The first assembling body 3 has a plurality of (e.g., five) formingroller pairs 31a to 31e that are continuously arranged in a row. Theforming roller pairs 31a to 31e have different forming surfaces, andsequentially form the metal strip 1, which is continuously supplied,into a substantially U-shaped metal pipe 1a having a longitudinal gap 16at its top portion, as shown in FIG. 2A.

The second assembling body 4 similarly has a plurality of (e.g., five)forming roller pairs 41a to 41e that are continuously arranged in a row.The forming roller pairs 41a to 41e respectively have fins 17, as shownin FIGS. 3A to 3C. The widths of the fins 17 are sequentially decreasedin the order from the forming roller pair 41a on a former stage to theforming roller pair 41e on a latter stage. The gap 16 of the metal pipe1a is engaged with the fins 17, and the gap 16 is decreased while beingpositioned to locate at the vertex of the metal pipe 1a. The gap 16 isabutted by the forming roller pair 41e on the final stage, therebyforming a metal pipe 1b which is closed almost completely at itsabutting portion 18, as shown in FIG. 2B.

FIG. 4 shows a partial sectional view of the optical fiber introducingmeans 6. An introducing tube 61 is provided to the optical fiberintroducing means 6. The introducing tube 61 serves as an optical fiberprotecting means that guides the optical fiber 5 and introduces it intothe metal pipe 1b. The proximal end of the introducing tube 61 ismounted to a tube connector 62. The introducing tube 61 extends throughthe metal pipe 1b, passes the welding position of the laser weldingmechanism 7, and reaches a welded, sealed metal pipe 1c. The introducingtube 61 has a double tube structure consisting of an inner tube 61a andan outer tube 61b. The inner tube 61a guides the optical fiber 5 to themetal pipe 1b and is connected to an inert gas supply tube 63a in thetube connector 62. The outer tube 61b is connected to a filler supplytube 63b in the tube connector 62. Thus, a filler can be supplied fromthe filler supply tube 63b into the outer tube 61b, and an inert gas canbe supplied from the inert gas supply tube 63a into the inner tube 61a.As the introducing tube 61 has the double tube structure, theintroduction path for the optical fiber and the filler is divided intoinner and outer tubes. Thus, even when the filler is charged at a highpressure, the filler will not leak from the loading port of the opticalfiber, thus increasing the yield of the filler. When an excessivetension is applied to the optical fiber, a crack is formed in theoptical fiber. However, in this embodiment, since a tension resultingfrom the influence of the viscosity of the filler is not applied to theoptical fiber, the problem of cracking can be solved. More specifically,the viscosity of the filler is changed by a temperature change. Thisvaries the rear tension of the fiber to change the extra length, causingvariations in extra length rate. However, as the optical fiberintroducing path and the filler introducing path are separated, thisproblem of variations in extra length rate can be solved.

The filler is called jelly, gel, a compound, or the like. A mineral oilor the like is used as the filler. The filler is charged as requiredinto the metal pipe that covers the optical fiber, and has a waterstopfunction and an optical fiber positioning function. In the presentinvention, such a filler is also used as a cooling agent required inwelding.

An inert gas is charged in the metal pipe that covers the optical fiberto purge hydrogen gas within the metal pipe. When the inert gas isflowed, the inert gas also serves as a cooling agent required inwelding.

The introducing tube 61 in the present invention not only guides theoptical fiber 5, but extends at least to the welding position, so thatit serves as a protection pipe for protecting the optical fiber frombeing inversely affected by the welding heat. Accordingly, theintroducing tube 61 is made of a metal having a high heat conductivity,e.g., copper or a copper alloy. The outer diameter of the introducingtube 61 is smaller than the inner diameter of the metal pipe 1b.

In this embodiment, the distal end of the introducing tube 61 passes thelaser welding mechanism 7 and is located before a spiral flaw detector81 of the measuring section 8. If the introducing tube 61 is passed toreach the spiral flaw detector 81, it can inversely influence the flowdetection precision. The distal end of the introducing tube 61 isinserted to a portion before the spiral flaw detector 81 in order toprevent this. However, when the flaw detection result will not beinversely affected even if the introducing tube 61 is inserted to reacha portion to pass the spiral flaw detector 81, for example, when themetal pipe has a large diameter and the introducing tube 61 is incontact with the wall surface, on the opposite side to the flawdetecting position, within the metal pipe, the introducing tube 61 maybe inserted such that its distal end exceeds the spiral flaw detector81, e.g., to reach a portion before the diameter reducing means 9.

As shown in FIG. 20, a plate spring mechanism 611 to face upward andbrought into elastic contact with the inner wall surface of the metalpipe 1b may be provided to the introducing tube 61 before and/or afterthe laser beam irradiating position of the laser welding mechanism 7.Alternatively, as shown in FIG. 21, the metal pipe 1b may be arranged atan upper position before and/or after the laser irradiating positiononly by a predetermined distance, or downward elasticity may be impartedto the introducing tube 61 itself. Hence, the introducing tube 61 isbrought into contact with the inner wall, on the opposite side to thelaser beam irradiating position, within the metal pipe 1b.

Regarding the elastic pressure contact of the introducing tube 61 withthe inner wall of the metal pipe 1b, it can be easily realized if theintroducing tube 61 is bent from state I to state II by the elasticityof its own against its original nature to extend straight, as shown inFIG. 22A, and is brought into contact with the inner surface wall of themetal pipe 1b in state II and maintained at this bent state by fixingthe optical fiber introducing means 6 at an appropriate position, asshown in FIG. 22B. At this time, a positioning mechanism 612 utilizing aspring mechanism or the like may be added to the optical fiberintroducing means 6 as required.

When the metal pipe 1b is to be arranged at an upper position before thelaser beam irradiating position by a predetermined distance, apositioning section 71 to be described later is finely adjusted. Whenthe metal pipe 1b is to be arranged at an upper position after the laserbeam irradiating position by a predetermined distance, a support rollstand 82 to be described later will be finely adjusted.

FIG. 5 shows the laser welding mechanism 7. The laser welding mechanism7 has the positioning section 71 for positioning the metal pipe 1b, anopening width adjusting section 100 for adjusting the opening width ofthe abutting portion 18, and a laser welding section 72.

The positioning section 71 has, e.g., two sets of guide shoes 73 and 74,a CCD seam monitor 75 provided between the guide shoes 73 and 74, and amicrometer 76 for finely adjusting the positions of the guide shoes 73and 74 in the vertical and horizontal directions.

As shown in FIG. 6A, the guide shoe 73 (74) has an upper shoe 73a (74a)and a lower shoe 73b (74b). The upper shoe 73a (74a) has a flat surfaceto be brought into contact with the metal pipe 1b. The lower shoe 73b(74b) has, e.g., a V-shaped groove to engage with the metal pipe 1b, andis biased upward by a spring (not shown).

The opening width adjusting section 100 has, e.g., a set of upper andlower squeeze shoes 104 and 102, a spring 106 for urging the lowersqueeze shoe 102 toward the metal pipe 1b, and a micrometer 112 foradjusting the urging force of the spring 106. The upper and lowersqueeze shoes 104 and 102 respectively have semicircular portions alongthe outer circumferential surface of the metal pipe 1b, as shown in thesectional view of FIG. 6B. The width of the gap 16 is adjusted byadjusting the urging force of the spring 106 by the micrometer 112. Whenthe gap 16 is adjusted by the squeeze shoe 104 arranged at 15 mm orless, especially 3 to 15 mm, from the welding portion, the laserweldability can be increased (this will be described later).

The positioning section 71 need not always be provided, and the openingwidth adjusting section 100 may also have a positioning function.

The laser welding section 72 has a laser irradiating means 77 and a gasseal means 78 for sealing the welding position of the metal pipe 1b withan inert gas, e.g., argon gas.

The laser irradiating means 77 is connected to, e.g., a carbon dioxidegas laser unit. The laser irradiating means 77 guides and focuses thelaser beam through an optical system and irradiates the laser beamtoward the surface of the metal pipe 1b at an angle of about 90°. Thelaser irradiating means 77 is adjusted such that the focal point of thelaser beam is formed below the abutting portion 18 located at the topportion of the metal pipe 1b, i.e., inside the metal pipe 1b (see FIG.8).

Referring back to FIG. 1, the measuring section 8 provided on the outputstage of the laser welding mechanism 72 has the support roll stand 82, aspeedometer 83, and the spiral flaw detector 81, and examines the weldedstate and the like.

The diameter reducing means 9 comprises roller dies and reduces theouter diameter of the welded, sealed metal pipe 1c to a predeterminedvalue, thereby forming the metal pipe 1c into a thin metal pipe 1d inaccordance with the outer diameter of the optical fiber 5. A tension isapplied to the metal pipe, which is to be diameter-reduced by thediameter reducing means 9, mainly by the forming means 2 and thediameter reducing means 9.

The tension changing means 11 provided on the output side of thediameter reducing means 9 comprises capstans having, e.g., a pair ofrolls 11a and 11b, as shown in FIGS. 7A and 7B. The surface of one roll11a is formed smooth. A plurality of grooves are formed in the surfaceof the other roll 11b, and the metal pipe 1d is wound on the roll 11b bya plurality of turns without overlapping. The tension adjusting means 13also comprises dancer roll stands having a pair of rolls 13a and 13b.When the distance between the rolls 13a and 13b is changed by moving theposition of one roll 13b in the direction indicated by an arrow, thetension of the metal pipe-covered optical fiber cable 12 on the outputside of the capstan 11 is adjusted.

Referring back to FIG. 1, the tension adjusting means 14 and 15 foradjusting the tension of the metal strip 1 supplied to the forming means2 and the tension of the optical fiber 5 supplied to the optical fiberintroducing port of the introducing tube 61 respectively comprise dancerstands. The dancer stands 14 and 15 change tensions by moving deadweights acting on pulleys 14a and 15a engaging with the metal strip 1and the optical fiber 5, respectively.

As shown in FIG. 24, the metal pipe length adjusting means 130 arrangedbetween the cable take-up machine 10 and the tension adjusting means 13has dies 132 through which the metal pipe 1d extends, an urging means134 for urging the dies 132 against the metal pipe 1d, and an urgingforce adjusting means 136, e.g., a micrometer, for adjusting the urgingforce of the urging means 134. The metal pipe length adjusting means 130extends the metal pipe 1d, from which the tension is removed by thetraction means, for a predetermined length by reducing its diameter,thereby adjusting the length of the optical fiber with respect to themetal pipe, i.e., adjusting the extra length. When the metal pipe isdiameter-reduced by the metal pipe length adjusting means 130, the extralength is adjusted without substantially applying any tension orexcessive tension to the optical fiber, so that damage to the opticalfiber is prevented, thereby prolonging the service life of the opticalfiber. The metal pipe-covered optical fiber cable 12 whose extra lengthis controlled is taken up by the take-up machine 10.

An operation of manufacturing the metal pipe-covered optical fiber cable12 by the manufacturing apparatus having the above arrangement will bedescribed in accordance with manufacturing steps.

The outline of the manufacturing operation will be described. As shownin FIG. 1, the metal strip 1 adjusted to a predetermined tension iscontinuously supplied to the forming means 2 and formed into the metalpipe 1a (forming step). The optical fiber 5 adjusted to thepredetermined tension is continuously supplied into the metal pipe 1a(optical fiber inserting step). The metal pipe 1b in which the opticalfiber 5 is mounted is laser-welded by the laser welding means 72 to sealits opening 18a (laser welding step). The sealed metal pipe 1c issubjected to predetermined measuring and inspection, and its diameter isreduced to a predetermined value by the diameter reducing means 9(measuring and diameter reducing step). The diameter-reduced metal pipe1d is pulled by the tension changing means 11 and the tension adjustingmeans 13 (traction step). The metal pipe 1d output from the tensionadjusting means 13 and from which the tension is removed passes throughthe metal pipe length adjusting means 130 so that its diameter isreduced, thereby performing extra length control (extra length controlstep). The metal pipe-covered optical fiber cable 12 obtained by extralength control is taken up by the cable take-up machine 10 (take-upstep). Each step will be described later in detail.

(1) Forming Step

As shown in FIG. 1, the metal strip 1 is continuously supplied to theforming means 2 while it is adjusted to a predetermined tension by thedancer stand 14. The first assembling body 3 forms the metal strip 1supplied thereto into the metal pipe 1a. The formed metal pipe 1a hasthe longitudinal gap 16 at its top portion. When this metal pipe 1a issent to the second assembling body 4, as shown in FIGS. 3A to 3C, thegap 16 of the metal pipe 1a is sequentially narrowed in accordance withthe widths of the fins 17 of the forming roller pairs 41a to 41d of thesecond assembling body 4. The gap 16 is abutted by the forming rollerpair 41e on the last stage, thereby forming the metal pipe 1b which iscompletely closed at the abutting portion 18. Note that after passingthe last forming roller pair 41e, the abutting portion 18 is opened dueto spring back of the metal pipe 1b.

(2) Optical Fiber Inserting Step

The optical fiber 5 adjusted to the predetermined tension by the dancerstand 15 is continuously supplied between the first and secondassembling bodies 3 and 4 from the introducing tube 61 inserted throughthe gap 16 in the metal pipe 1a. In FIG. 4, when the optical fiber issupplied, the filler is supplied from the tube 63b into the outer tube61b, and an inert gas, e.g., argon gas, helium gas, nitrogen gas, or thelike is supplied from the tube 63a into the inner tube 61a.

(3) Laser Welding Step

The metal pipe 1b inserted in the introducing tube 61 is sent to thepositioning section 71. The metal pipe 1b sent to the positioningsection 71 is guided as it is engaged with the grooves in the guideshoes 73 and 74. Accordingly, transverse shift, rotation, andfurthermore meandering of the metal pipe 1b can be prevented. Positionaldisplacement of the abutting portion 18 was observed by the CCD seammonitor 75. When guide rollers were used, the abutting portion 18shifted for as large as ±100 μm by torsion. In contrast to this, whenthe guide shoes were used, the abutting portion 18 shifted as small as±15 μm.

Subsequently, the CCD seam monitor 75 detects the position of theabutting portion 18 of the metal pipe 1b. The position of the micrometer76 is detected from the detection result of the abutting portion 18. Themicrometer 76 is automatically or manually operated in accordance withthe detection result to move the guide shoes 73 and 74. Fine adjustmentis performed such that the abutting portion 18 is set at a predeterminedposition with respect to the focal point of the laser beam.

The role of the positioning section 71 will be described in detail. Asdescribed previously, the guide shoes 73 and 74 of the positioningsection 71 prevent rotation or meandering of the metal pipe 1b, andguide the abutting portion 18, precisely located with respect to thelaser irradiating position by the finned forming roller pairs 41a to41d, to the laser irradiating position without causing the metal pipe 1bto wind. As described previously, the metal pipe 1b can be arranged atan upper portion before the laser beam irradiating position by apredetermined distance by adjusting the positioning section 71. As aresult, the introducing tube 61 can be firmly brought into elasticcontact with the inner wall surface of the metal pipe 1b. Thus, theadverse influence of laser welding can be minimized, as described above,and a long-term continuous manufacturing operation can be performed.

As shown in FIG. 23, the metal pipe 1b is arranged above or below a pathline by a predetermined distance or more (but within the range of theelastic limit) by the positioning section 71 by using support rolls 82aand 82b of the support roll stand 82 and the last forming roller pair41e as two fulcrums, so that the metal pipe 1b constitutes two sides ofa substantial triangle. At this time, a light tension is applied to themetal pipe 1b located between the support roll stand 82 and the lastforming roller pair 41e. This means that the positioning section 71serves as a means for adjusting the tension of the metal pipes(especially the metal pipes 1c and 1d) just like the metal strip tensionadjusting means 14 to be described later. This suppresses vibration ofthe metal pipe 1b at the laser welding position (indicated by a mark Xin FIG. 23).

At the laser irradiating position, another CCD monitor (not shown) wasactually installed at a position inclined by 90° from the CCD seammonitor 75 and the path line as the center, and vertical vibration ofthe metal pipe 1b was observed. As a result, the following facts wereconfirmed. When the guide shoes 73 and 74 of the positioning section 71were open, the metal pipe 1b vibrated by about ±100 to ±150 μm. When themetal pipe 1b was fixed by the guide shoes 73 and 74, the metal pipe 1bvibrated by about ±20 to ±30 μm. When the positioning section 71 wasadjusted as shown in FIG. 23A or 23B, the metal pipe 1b vibrated byabout ±5 μm.

When elastic contact of the introducing tube 61 with the inner wallsurface of the metal pipe 1b is considered, it is preferable to adjustthe positioning section 71 as in FIG. 23A rather than as in FIG. 23B. Bythis adjustment, high-degree welding control is enabled, and the adverseinfluence of welding is further decreased, thus contributing to along-term operation.

The metal pipe 1b, the position of the abutting portion 18 of which isadjusted in this manner, is supplied to the opening width adjustingsection 100. More specifically, the abutting portion 18 is opened due tospring back of the metal pipe 1b. The width of the opening 18a largelyinfluences weldability as well as the welding rate, the laser power, andthe focus shift amount of the laser beam. Thus, the opening width isadjusted by the opening width adjusting section 100. The opening widthis determined by the urging force of the urging means (micrometer) 112and the distance of the squeeze shoes 102 and 104 from the weldingposition. When the plate thickness is large, the optimum opening widthof the welding portion is larger than that obtained when the platethickness is small. Therefore, when the plate thickness of the metalpipe is small, that is, when a large opening width is set, the urgingforce of the micrometer 112 is set to be comparatively small, and/or thedistance of the squeeze shoes 102 and 104 from the welding position isset to be comparatively large. Inversely, when the plate thickness issmall, that is, when a small opening width is set, the urging force ofthe micrometer 112 is increased, and/or the distance of the squeezeshoes 102 and 104 from the welding position is decreased. Generally, thesqueeze shoes 102 and 104 are preferably provided at 15 mm or less fromthe welding position. When the distance from the welding positionexceeds 15 mm, the width of the opening 18a is increased at the weldingposition due to spring back of the metal pipe 1b, making it difficult toadjust the width of the opening 18a to a desired value. The squeezeshoes 102 and 104 must be provided at 3 mm from the welding position atthe nearest. If the distance from the welding position becomes less than3 mm, the squeeze shoes 102 and 104 will be thermally influenced by thelaser beam. FIG. 25 shows the influence of the distance from the weldingposition on the weldability. In FIG. 25, the distance of the squeezeshoes 102 and 104 from the welding position is plotted along the axis ofabscissa (unit: mm), and the welding rate (unit: m/min) is plotted alongthe axis of ordinate, while other welding conditions are set the same.From FIG. 25, the following facts are obtained. With a metal pipe of 1.4mmφ×0.1t, the maximum welding rate of 15 m/min can be obtained when thedistance of the squeeze shoes 102 and 104 from the welding position is 5mm in the range of 3 to 7 mm, which is larger than the conventionalwelding rate (12 m/min) obtained under the same conditions. With a metalpipe of 2.4 mmφ×0.15t, the maximum welding rate of 9 m/min can beobtained when the distance of the squeeze shoes 102 and 104 from thewelding position is 7 mm in the range of 4.5 to 10 mm, which is largerthan the conventional welding rate (7 m/min) obtained under the sameconditions. With a metal pipe of 3.6 mmφ×0.2t, the maximum welding rateof 6 m/min can be obtained when the distance of the squeeze shoes 102and 104 from the welding position is 10 mm in the range of 5 to 15 mm,which is larger than the conventional welding rate (4 m/min) obtainedunder the same conditions. The opening width is usually adjusted withinthe range of 0 to 150 μm, although it depends on other weldingconditions as well.

The metal pipe 1b, the opening width of the opening 18a of which isadjusted by the opening width adjusting section 100, is fed to the laserwelding means 72. In the laser welding means 72, a laser beam isirradiated from the laser irradiating means 77 while argon gas issupplied from the gas seal means 78 to the opening 18a of the metal pipe1b, thereby welding the opening 18a. The inner surface of the weldingsection is sealed by the argon gas which flows in the introducing tube61 and is injected from the distal end of the introducing tube 61 toflow back. An increase in temperature of the optical fiber 5 isminimized by cooling the optical fiber 5 with the argon gas flowing inthe introducing tube 61 and flowing back from the distal end of theintroducing tube 61. After this, the argon gas is charged in the metalcover pipe to purse hydrogen gas that adversely influences the opticalfiber.

The introducing tube 61 that guides the optical fiber 5 is disposed suchthat it is brought into elastic contact with the inner wall, on theopposite side to the laser beam irradiating position, of the metal pipe1b before and after the laser beam irradiating position, and a gap isprovided between the inner surface of the opening 18a and theintroducing tube 61. Thus, heat shielding is performed by this gap andthe introducing tube 61, thereby decreasing the influence of heat on theoptical fiber 5.

When the introducing tube 61 is to be arranged on the opposite side tothe opening of the metal pipe in the laser welding section 72, if thepositioning section 71 is adjusted to locate the metal pipe 1b above thepath line, the arrangement of the introducing tube 61 described abovecan be realized more elastically.

When the introducing tube 61 and the optical fiber 5 are cooled by thefiller flowing in the introducing tube 61, an increase in temperature ofthe introducing tube 61 and the optical fiber 5 can be minimized. As aresult, the service life of the introducing tube 61 can be prolonged, sothat an elongated metal pipe-covered optical fiber can be manufactured,and quality degradation of the optical fiber caused by the influence ofthe laser heat is prevented. After this, the filler is charged in themetal cover pipe, so that water will not enter the metal pipe-coveredoptical fiber and the metal pipe-covered optical fiber will bepositioned by the filler.

For example, the temperature near the optical fiber 5, which isconventionally increased to 600° or more when the introducing tube 61 isin contact with the opening 18a at the laser irradiating position, canbe decreased to about 115° C. to 135° C. by providing the above gap, andcan be decreased to about 100° C. by flowing the filler.

The adverse influence of spatter, deposited on the introducing tube 61,on welding can be delayed by providing the above gap, so that stablewelding can be performed for a long period of time.

The laser beam irradiated by the laser irradiating means 77 is adjustedto form its focal point inside the metal pipe 1b. Thus, the powerintensity of the laser beam irradiated toward the opening 18a can beprevented from excessively increasing, thereby allowing stable welding.

As the focal point of the laser beam is formed inside the metal pipe 1b,once the cavity is formed, the laser beam which is reflected by thecavity wall is focused toward the bottom portion of the cavity, so thata deep cavity is formed. Thus, the melting width can be set almostconstant, and the rear bead width can be narrowed.

When the focal shift amount of the laser beam which is irradiated at aconstant power is set within a predetermined range, thus controlling theirradiation power intensity, and the welding rate is determined inaccordance with the focal shift amount, e.g., the irradiation powerintensity, the rear bead width is decreased, thereby suppressing theadverse influence of spatter.

Since no non-welding portion remains at the opening 18a, a minimum valueb_(min) of the rear bead width is fixed, and a maximum value b_(max) ofthe rear bead width is fixed at a limit where no adverse influence ofspatter occurs even after a long-term operation.

As has been described previously, in the abutting portion 18 of themetal pipe 1b, the opening 18a is formed at the position of the laserwelding section 72 due to spring back of the metal pipe 1b, as shown inFIG. 8. Spring back that causes this opening 18a is influenced by therigidity of the metal pipe 1b, i.e., by an outer diameter d of theformed metal pipe 1b. FIG. 9 shows a result obtained by examining therelationship between the outer diameter d (mm) and the rear bead width b(μm) by irradiating a laser beam having a power of 400 (W) to theopening 18a to perform welding while the metal pipe 1b made of Fe-basedstainless steel and having a longitudinal modulus of 18,000 (kg/mm²) iscompletely fixed. The tube outer diameter d is plotted along the axis ofabscissa, and the rear bead width b is plotted along the axis ofordinate. In FIG. 9, ∘ indicates a case wherein a non-welded portiondoes not occur, and x indicates a case wherein a non-welded portionoccurs. Accordingly, a straight line A indicates a limit where anon-welded portion does not occur. The straight line A is b=10d.

In an actual apparatus, it was obvious from observation using the CCDseam monitor 75 that a relative shift of about ±5 μm occurred betweenthe laser beam and the opening 18a due to small vibration of theapparatus and the like.

Thus, the minimum width b_(min) of the rear bead becomes 10d±5 μm. Forexample, when the outer diameter of the metal pipe 1b is 1 mm, theminimum width b_(min) of the rear bead is 20 μm.

In the above description, the minimum width of the rear bead b_(min)=10d±5 μm is obtained when the metal pipe 1b is made of Fe-basedstainless steel having a longitudinal modulus of 18,000 (kg/mm²). Evenif Fe-based stainless steel or an Ni-based alloy having a longitudinalmodulus of 18,000 (kg/mm²) or more is used, high-quality welding notcausing a non-welded portion can be performed by increasing the rearbead width to be larger than the minimum width b_(min).

The limit where no adverse influence of spatter occurs even after along-term operation is determined by the shape of the melt zone. FIG. 10shows a result obtained by examining the relationship between the tubewall thickness t (mm) and the rear bead width b (μm) by irradiating alaser having a power of 400 (W) to the opening 18a to perform welding.The tube wall thickness t is plotted along the axis of abscissa, and therear bead width b is plotted along the axis of ordinate. In FIG. 10, ∘indicates a case wherein no adverse influence of spatter occurs andwelding can be continuously performed for a long period of time, e.g.,for 10 hours, and x indicates a case wherein spatter occurs andlong-term welding cannot be performed. Note that ten hours describedabove correspond to the maintenance timing of the actual operation anddo not specify the limit time where no adverse influence of spatteroccurs.

Accordingly, a straight line B indicates a limit where no adverseinfluence of spatter occurs even after a long-term operation. Thestraight line B is b=1000(t/2). Thus, when the tube wall thickness t is0.1 mm, the allowable maximum rear bead width b_(min) is 50 μm.

In this manner, when a laser beam having a power of 400 (W) is used andthe metal pipe 1b has a wall thickness of 0.1 mm and an outer diameterof 1 mm, if welding is performed by controlling the rear bead width b to20 to 50 μm, an adverse influence of spatter is suppressed even after along-term operation, thereby continuously performing welding free fromdefects.

In order to set the rear bead width b within a predetermined range inthis manner, the focal shift of the laser beam irradiated toward theabutting portion 18 must be performed in accordance with the size of themetal pipe 1b, thereby controlling the irradiation power intensity.

The welding rate is determined by the condensing diameter of the laserbeam, i.e., the focal shift amount, and the overlap ratio.

FIGS. 11, 12, and 13 show the results obtained by examining casessatisfying the condition of minimum value b_(min) ≧10d±5 μm and thecondition of maximum rear bead width b_(max) ≦1000(t/2) and cases notsatisfying these conditions, while changing the size of the metal pipe1b. In FIGS. 11, 12, and 13, the welding rate V (m/min) is plotted alongthe axis of abscissa, and the focus shift amount F (mm) is plotted alongthe axis of ordinate. FIGS. 11 to 13 respectively show a case whereinthe outer diameter d and the tube wall thickness t of the metal pipe 1bare 3.5 mm and 0.2 mm, respectively, a case wherein the outer diameter dand the tube wall thickness t of the metal pipe 1b are 2.0 mm and 0.15mm, respectively, and a case wherein the outer diameter d and the tubewall thickness t of the metal pipe 1b are 1.0 mm and 0.1 mm,respectively. In FIGS. 11 to 13, ∘ indicates a case wherein theseconditions are satisfied, and x indicates a case wherein theseconditions are not satisfied. The limits where these conditions aresatisfied and not satisfied are indicated by curves A and B. The curve Aindicates the minimum appropriate rear bead width b_(min) =10d±5 μm, andthe curve B indicates the maximum appropriate rear bead width b_(max)=1000(t/2).

As shown in FIG. 11, when the outer diameter d and the tube wallthickness t of the metal pipe 1b are 3.5 mm and 0.2 mm, respectively,the allowance is the largest when the focus shift amount F falls withinan appropriate range of F=0.85 mm to F=1.45 mm. Hence, when welding isperformed by setting the focus shift amount within this range and thewelding rate V to 4 (m/min), welding can be performed for a long periodof time without being influenced by spatter while suppressing the rearbead width b within a predetermined range of 40 to 400 μm.

Similarly, when the outer diameter d and the tube wall thickness t ofthe metal pipe 1b are 2.0 mm and 0.15 mm, respectively, welding may beperformed by setting the focus shift amount F within the range of 0.8 to1.3 mm and the welding rate V to 6 (m/min). When the outer diameter dand the tube wall thickness t of the metal pipe 1b are 1.0 mm and 0.1mm, respectively, welding may be performed by setting the focus shiftamount F to 0.7 to 1.1 mm and the welding rate V to 10 (m/min),respectively. High-quality welding can be continuously performed in thismanner. The size of the opening 18a of the abutting portion 18 of themetal pipe 1b will slightly vary depending on the extra length controlconditions (to be described separately) and setting of the positioningsection 71 (FIGS. 23A and 23B). When the positioning section 71 is setas shown in FIG. 23A, the size of the opening 18a is increased; when thepositioning section 71 is set as shown in FIG. 23B, the size of theopening 18a is decreased.

To perform high-quality welding continuously, the welding conditions,e.g., the welding rate, the irradiation power intensity of the laserbeam, the focus shift amount, and the like must be selected, asdescribed above. An optimum opening (opening for welding) 18a changesdepending on the preset welding conditions. Therefore, the opening 18aof the abutting portion 18 of the metal pipe 1b is adjusted by theopening width adjusting section 100 to an optimum value, and the metalpipe 1a is fed to the welding section. Adjustment of the opening widthhas already been described, and a detailed description thereof will beomitted here.

(4) Measuring and Diameter Reducing Step

The metal pipe 1c, which is sealed as its opening 18a and welded, is fedto the measuring section 8. In the measuring section 8, the passingspeed, i.e., the welding rate V of the metal pipe 1c is measured by thespeedometer 83 while the metal pipe 1c is supported by the support rollstand 82. The welding state is examined by the spiral flaw detector 81.

After passing the spiral flaw detector 81, the metal pipe 1c isdiameter-reduced to a predetermined size by the diameter reducing means9 in accordance with the outer diameter of the incorporated opticalfiber 5. When the metal pipe 1c is to be diameter-reduced by thediameter reducing means 9, as only one introducing tube 61 having adouble tube structure is inserted in the metal pipe 1c up to a positionimmediately before the spiral flaw detector 81, the metal pipe 1c can beeasily diameter-reduced to the predetermined size. While the metal pipe1c is diameter-reduced by the diameter reducing means 9, a tension isapplied to the metal pipe 1c mainly by the forming means 2 and thediameter reducing means 9.

(5) Traction Step

Prior to continuous operation of this apparatus, when the metalpipe-covered optical fiber cable 12 is to be taken up by the cabletake-up machine 10, the sealed, diameter-reduced metal pipe 1d and theoptical fiber 5 must be engaged with each other. For this purpose,before the continuous operation, the welded, sealed metal pipe 1d ismanually wound on the capstans 11a and 11b of the tension changing means11 by a predetermined number of turns and pulled, and the distal end ofthe metal pipe 1d is mounted on the cable take-up machine 10 through thetension adjusting means 13. In this state, the distal end of the opticalfiber 5 is inserted up to the position before the capstan 11a. The metalpipe 1d is pressed at this position, thereby engaging the optical fiber5 with the inner side of the metal pipe 1d. Thereafter, the metal pipe1d is taken up by driving the capstan 11, so that the optical fiber 5 iswithdrawn from the introducing tube 61 together with the metal pipe 1d.

During the continuous operation, the metal pipe 1d diameter-reduced bythe diameter reducing means 9 passes through the tension changing means11 and the tension adjusting means 13. The tension adjusting means 13removes the tension applied to the metal pipe 1d.

(6) Extra Length Control Step

When the metal pipe 1d is wound on the capstans 11a and 11b and pulled,a tension acts on the metal pipe 1d due to the frictional force betweenthe metal pipe 1d and the capstans 11a and 11b. This frictional force islarge at the start of winding and is gradually decreased in accordancewith an increase in number of turns. Accordingly, the tension is largeat the start of winding and is gradually decreased. An elongationcorresponding to this tension occurs in the winding portion of the metalpipe 1d.

For example, in an ordinary operation, assume that a stainless steelstrip 1 having a width of 4 mm and a thickness of 0.1 mm is formed intoa metal pipe 1c having an outer diameter of 1.3 mm, and is drawn into ametal pipe 1d having an outer diameter of 1.0 mm. When the tension ofthe metal strip 1 is adjusted by the metal strip tension adjusting means14 such that the tension of the metal pipe 1c on the input side of thecapstan 11a becomes about 20 kgf, an elongation of +0.30% occurs in themetal pipe 1d due to the tension of the metal strip. At this time, ifthe tension of, e.g., an optical fiber 5 having an outer diameter of 250μm is adjusted by the optical fiber tension adjusting means 15 so that atension of about 25 gf acts on the optical fiber 5 on the input side ofthe capstan 11a, an elongation of +0.03% occurs in the optical fiber 5.

FIG. 14 shows the result obtained by studying the relationship among thenumber of turns of the metal pipe 1d on the capstans 11a and 11b, theelongation of the metal pipe 1d, and the elongation of the optical fiber5. In FIG. 14, the number of turns of the metal pipe 1d on the capstans11a and 11b is plotted along the axis of abscissa, and the elongation(%) of the metal pipe 1d is plotted along the axis of ordinate. A curveE indicates the change characteristics of the elongation of the metalpipe 1d, and a curve F indicates the change characteristics of theelongation of the optical fiber 5. As indicated by the curve F, when themetal pipe 1d is wound on the capstans 11a and 11b by six turns, theelongation occurring when the metal pipe 1d is supplied to the tensionadjusting means 13 becomes very small finally. As indicated by the curveF, when the optical fiber 5 is wound by one and half turns, itselongation becomes almost 0.

In this manner, when the optical fiber 5 is wound by one and half turnsso that its elongation becomes 0, the metal pipe 1d has an elongation of+0.19%. Immediately after the metal pipe 1d is wound on the capstans 11aand 11b by six turns, since its tension becomes almost 0, its elongationalso becomes almost 0. More specifically, after being wound by sixturns, the metal pipe 1d shrinks by 0.19% as compared to the shrinkageobtained after it is wound by one and half turns. The tension of theoptical fiber 5 is almost 0 after the optical fiber 5 is wound by oneand half turns. Accordingly, no change occurs in elongation of theoptical fiber 5 after winding, and thus the length of the optical fiber5 does not change. Therefore, after the metal pipe 1d is wound by sixturns, the optical fiber 5 is longer than the metal pipe 1d by about0.19%.

The winding diameter of the metal pipe 1d to be wound on the capstans11a and 11b and the winding diameter of the optical fiber 5 engagingwith the inner wall of the metal pipe 1d differ. Thus, when, e.g., thediameter of the capstans 11a and 11b is about 500 mm, the optical fiber5 has an elongation larger than that of the metal pipe 1d by about+0.09%. This elongation of 0.09% is canceled by 0.19% described above.As a result, the optical fiber 5 becomes longer than the metal pipe 1dby 0.10%.

A curve F1 of FIG. 15 shows an example of the change characteristics ofthe elongation of the optical fiber 5. The curve F1 is obtained when thetension of the optical fiber 5 is changed by the tension adjusting means15 so that it is increased on the input side of the capstan 11a, whilethe tension of the metal pipe 1d on the input side of the capstan 11a iskept unchanged as in FIG. 14. The curve F1 indicates that when theoptical fiber 5 is wound on the capstans 11a and 11b by 3 and halfturns, its tension becomes almost 0. Meanwhile, the elongation of themetal pipe 1d is 0.09% after the metal pipe 1d is wound by 3 and halfturns. When the elongation of 0.09% of the metal pipe 1d and theelongation of 0.09% of the optical fiber 5 caused by the difference inwinding diameter are canceled with each other, the elongation of themetal pipe 1d and that of the optical fiber 5 become the same, and adifference in length between the metal pipe 1d and the optical fiber 5,that is, the extra length becomes 0%.

A curve E1 of FIG. 16 shows the change characteristics of the elongationof the metal pipe 1d. The curve E1 is obtained when, as opposed to thecase of FIG. 15, the tension of the optical fiber 5 on the input side ofthe capstan 11a is not changed but the tension is applied to the metalstrip 1 by the tension adjusting means 14, thereby increasing thetension on the metal pipe 1d on the input side of the capstan 11a.

A curve E2 of FIG. 16 shows the change characteristics of the elongationof the metal pipe 1d. The curve E2 is obtained when the tension of themetal pipe 1d on the output side of the capstans 11a and 11b isincreased by the tension adjusting means 13 while the tension of themetal pipe 1d on the input side of the capstan 11a is the same as thatof the case of FIG. 14. A curve E3 of FIG. 16 shows the changecharacteristics of the elongation of the metal pipe 1d obtained when thetension of the metal pipe 1d is increased both on the input and outputsides of the capstans 11a and 11b.

In this manner, when the tension of the metal pipe 1d on one or both ofthe input and output sides of the capstans 11a and 11b are increased bya predetermined value, the length of the optical fiber 5 can beincreased to be larger than that of the metal pipe 1d by a desiredamount. For example, in the case indicated by the curve E3, when themetal pipe 1d is wound on the capstans 11a and 11b by one and halfturns, its elongation is +0.26%. Thus, the optical fiber 5 can beincreased to be larger than the metal pipe 1d by 0.17% on the outputside of the capstans even if the elongation of 0.09% caused by thewinding diameter of the optical fiber 5 is canceled.

A curve F2 of FIG. 17 shows the change characteristics of the elongationof the optical fiber 5 obtained by further increasing the tension of theoptical fiber 5 on the capstan input side than in the case shown in FIG.15. The curve F2 indicates that the optical fiber 5 can be made shorterthan the metal pipe 1d. In this case, the elongation of the opticalfiber 5 becomes 0 when it is wound by 5 turns, and the elongation of themetal pipe 1d obtained at this time is +0.04%. This elongation of +0.04%is canceled by the winding difference of 0.09% of the optical fiber 5.As a result, the optical fiber 5 can be made shorter than the metal pipe1d by 0.05%.

As described above, when the capstans 11a and 11b on which the metalpipe 1d is wound by a plurality of turns, the tension adjusting means 14for the metal strip 1, the tension adjusting means 15 for the opticalfiber 5, and in some cases the tension adjusting means 13 on the outputside of the capstans 11a and 11b are totally adjusted, so that thelength of the optical fiber 5 with respect to the metal pipe 1d can bearbitrarily adjusted. When the tension of the metal pipes 1c and 1d isadjusted by adjusting the positioning section 71 in the same manner asin adjusting the tension adjusting means 14 for the metal strip 1, extralength control can be performed at a higher precision. The function ofthe positioning section 71 in extra length control in this case isidentical to that of the extra length control function of the tensionadjusting means 14 for the metal strip 1, and thus a detaileddescription thereof will be omitted.

In the above example, extra length control for the metal pipe 1d havingan outer diameter of 1.08 mm and a thickness of 0.1 mm and the opticalfiber 5 having an outer diameter of 250 μm is described. Table 1 showsthe elongation (%) of the metal pipe 1d and the elongation (%) of theoptical fiber 5 on the input side of the capstans 11 which are obtainedwhen the extra length is set to 0% by changing the outer diameter andthickness of the metal pipe 1d and the outer diameter of the opticalfiber 5.

                  TABLE 1                                                         ______________________________________                                                                            Differ-                                                                       ence in                                   Outer               Elonga-         Circum-                                   Diameter/  Diameter tion in   Elonga-                                                                             ferential                                 Thickness of                                                                             of Fiber Metal     tion in                                                                             Length                                    Metal Pipe (mm)     Pipe      Fiber (%)                                       ______________________________________                                        2.4/0.2    1.6      0.24      0.10  0.07                                       1.7/0.15  0.25     0.26      0.07  0.15                                      0.7/0.1    0.25     0.35      0.20  0.05                                      ______________________________________                                    

Table 1 indicates that extra length control can be performed with apredetermined extra length rate even by using a metal pipe 1d and anoptical fiber 5 having arbitrary sizes.

However, since the optical fiber is made of glass, when a large tensionis applied to the optical fiber to increase the length of the opticalfiber, a small crack is formed due to the residual strain (stress)occurring in the optical fiber. Then, the optical fiber may be damagedto prolong its service life. Hence, when the optical fiber is used undersevere conditions so that the manufacturing specifications requirestrictness, for example, when the optical fiber is used as an underseascable, extra length control must be performed by minimizing a tension tothe optical fiber. In this case, the metal pipe 1d from which a tensionis removed is diameter-reduced by the metal pipe length adjusting means130 shown in FIGS. 1 and 24, thereby adjusting its length, and extralength control is performed without applying a substantial or largetension to the optical fiber. When extra length control is performed bythe metal pipe length adjusting means 130, the length of the opticalfiber with respect to the metal pipe, i.e., the extra length, can beadjusted without elongating the optical fiber. As a result, damage tothe optical fiber can be avoided, and the service life of the opticalfiber can be prolonged.

Especially, when a filler is charged into the metal pipe from theintroducing tube 61, the optical fiber 5 which is introduced togetherwith the filler receives a tension due to the variations in change inviscosity resistance of the filler. When the optical fiber is introducedfrom the inner tube 61a of the introducing tube 61 and the filler isintroduced from the outer tube 61b, thus providing a double tubestructure as in the embodiment, the optical fiber will not receive anytension caused by the viscosity resistance of the filler when chargingthe filler. Therefore, damage to the optical fiber can be reliablyprevented by the combination of the metal pipe length adjusting means130 and the introducing tube 61 having the double tube structure.

Table 2 shows an example in which the length of the metal pipe isadjusted (extra-length controlled) by the metal pipe length adjustingmeans 130. From Table 2, arbitrary extra length adjustment can beapparently performed in accordance with the product specifications.

                  TABLE 2                                                         ______________________________________                                        Outer    Outer               Product Amount                                   Diameter/                                                                              Diameter/                                                                              No Extra   Specifi-                                                                              of                                       Thickness                                                                              Thickness                                                                              Length     cations Extra                                    of Pipe  of       Adjust-    with Extra                                                                            Length                                   Element  Product  ment       Length  Adjust-                                  (mm)     (mm)     %          Adjustment                                                                            ment %                                   ______________________________________                                        3 6/0.2  2.8/0.2  +0.2       0       -0.2                                      2.4/0.15                                                                               1.7/0.15                                                                              +0.3       -0.1    -0.4                                     1.4/0.1  0.9/0.1  +0.4       +0.15   -0.25                                    ______________________________________                                    

(7) Take-up Step

The metal pipe-covered optical fiber cable 12 obtained by extra lengthcontrol is taken up by the cable take-up machine 10.

As has been described above, according to the apparatus and method ofthe present invention, the length of the metal pipe is adjusted bydiameter reduction of the metal pipe from which a tension is removed,thereby performing extra length control of the metal pipe with respectto the optical fiber. Thus, any tension need not be applied to theoptical fiber for the purpose of extra length control. Therefore, anexcessive tension is not applied to the optical fiber, or substantiallyno tension need be applied to the optical fiber, so that cracking can beprevented, thereby prolonging the service life of the optical fiber.

In the above embodiment, the optical fiber introducing means 6 isprovided between the first and second assembling bodies 3 and 4 of theforming means 2. However, as shown in FIG. 18, an optical fiberintroducing means 6 may be provided before the first assembling body 3,and an introducing tube 61 may be inserted before a forming roller pair31a of the initial stage.

In the above embodiment, the half split type squeeze shoes 102 and 104are provided to adjust the width of the opening 18a of the metal pipe.However, the present invention is not limited to this, and the squeezeshoe may be divided into three or more parts. In the embodiment, thesplit type squeeze shoes 102 and 104 are arranged vertically. However,the present invention is not limited to this, and split type shoes maybe provided horizontally. Also, a layer having a small frictioncoefficient may be formed on the inner circumferential surface of eachsqueeze shoe.

Furthermore, in the above embodiment, the traction means comprising thecapstans 11a and 11b of the tension changing means 11 and the tensionadjusting means 13 is directly provided after the diameter reducingmeans 9, and the tension of the metal pipe 1d on the input and outputsides of the capstans 11a and 11b and the tension of the optical fiber 5on the capstan input side are adjusted by the capstans 11a and 11b andthe tension adjusting means 14, 15, and 13 while pulling the metalpipe-covered optical fiber cable 12, thereby performing extra lengthcontrol. However, as shown in FIG. 19, a means 19 for pulling the metalpipe 1d may be provided before capstans 11a and 11b, so that the tensionof the metal pipe 1d on the capstan input side can be arbitrarilychanged. As the pulling means 19, for example, infinite track typecapstans may be used, and the metal pipe 1d may be pulled as it issandwiched by the capstans, so that the metal pipe 1d can be pulled witha tension required in the forming schedule. The tension of the metalpipe 1d to be supplied to the capstan 11a can be arbitrarily controlledby adjusting the feed speed of the infinite track type capstans.

After the optical fiber 5 is manufactured, if the optical fiber 5 issubjected to secondary forming in a later step, the extra length maybecome sometimes different from the target value, so that extra lengthcontrol must be performed. In this case, extra length control may beperformed while considering the difference in extra length value,thereby obtaining an optical fiber having an appropriate extra lengthafter secondary forming.

In the above embodiments, one optical fiber is introduced in a metalpipe. However, an optical fiber bundle comprising a plurality of opticalfibers can be introduced in the same manner.

Additional advantages and modifications will readily occur to thoseskilled in the art. Therefore, the invention in its broader aspects isnot limited to the specific details, representative devices, andillustrated examples shown and described herein. Accordingly, variousmodifications may be made without departing from the spirit or scope ofthe general inventive concept as defined by the appended claims andtheir equivalents.

What is claimed is:
 1. An apparatus for manufacturing an optical fibercable covered with a metal pipe, comprising:forming means for forming ametal strip into a metal pipe having a slit type opening by abutting twosides of the metal strip; opening width adjusting means, arrangeddownstream of said forming means, for adjusting a width of the openingto a predetermined size; welding means, having means for irradiating themetal pipe at the width adjusted opening with a laser beam, for forminga sealed metal pipe by welding the abutting two sides in the vicinity ofthe width adjusted opening; and optical fiber introducing means forintroducing an optical fiber or an optical fiber bundle into the sealedmetal pipe; wherein said opening width adjusting means includes meansfor adjusting the width of the opening to the predetermined size inaccordance with at least one of a diameter, thickness and composition ofthe metal strip and in accordance with at least one of a welding rate,laser beam power and laser beam focus shift amount of said weldingmeans; wherein said opening width adjusting means comprises squeeze shoemeans, having an inner circumferential surface, for squeezing the metalpipe as the metal pipe passes therethrough, said inner circumferentialsurface having a shape conforming to an outer circumferential surface ofthe metal pipe; and wherein said squeeze shoe means comprises:an uppersqueeze shoe and a lower squeeze shoe; urging means for urging saidlower squeeze shoe toward the metal pipe; and urging force adjustingmeans for adjusting an urging force of said urging means.
 2. Anapparatus according to claim 1, wherein said squeeze shoe means isprovided at a distance of from 3 mm to 15 mm from a welding position ofsaid welding means.
 3. An apparatus according to claim 1, furthercomprising positioning means, provided between said forming means andsaid opening width adjusting means, for positioning the opening of themetal pipe above or below a focal point of a laser beam at apredetermined distance therefrom.
 4. An apparatus according to claim 1,wherein said introducing means comprises:an optical fiber introducingand protecting tube inserted through the opening in the metal pipe forintroducing the optical fiber or the optical fiber bundle into the metalpipe and for protecting the optical fiber or the optical fiber bundlefrom welding heat generated by said welding means; and means forelastically pressing said optical fiber introducing and protecting tubeagainst an inner wall of the metal pipe on a side opposite to a surfacethereof irradiated with the laser beam of said welding means.
 5. Anapparatus according to claim 4, wherein said optical fiber introducingand protecting tube extends through the metal pipe at least to a weldingposition of said welding means to thereby introduce the optical fiber orthe optical fiber bundle into the sealed metal pipe and protect theoptical fiber or the optical fiber bundle from the welding heatgenerated by said welding means.
 6. A method of manufacturing an opticalfiber cable covered with a metal pipe, comprising the steps of:forming ametal strip into a metal pipe having a slit type opening by abutting twosides of the metal strip; adjusting an opening width of the opening to apredetermined size; welding the width adjusted opening to form a sealedmetal pipe by irradiating the abutting two sides of the metal pipe inthe vicinity of the width adjusted opening with a laser beam; andintroducing an optical fiber or an optical fiber bundle into the sealedmetal pipe; wherein the opening width adjusting step comprises adjustingthe width of the opening to the predetermined size in accordance with atleast one of a diameter, thickness and composition of the metal stripand in accordance with at least one of a welding rate, laser beam powerand laser beam focus shift amount of said welding step; and wherein theopening width adjusting step comprises adjusting the width of theopening with a squeeze shoe means having an inner circumferentialsurface for squeezing the metal pipe as the metal pipe passestherethrough, said inner circumferential surface having a shapeconforming to an outer circumferential surface of the metal pipe, andsaid squeeze shoe means comprising:an upper squeeze shoe and a lowersqueeze shoe; urging means for urging said lower squeeze shoe toward themetal pipe; and urging force adjusting means for adjusting an urgingforce of said urging means.
 7. A method according to claim 6, furthercomprising the steps of:setting a distance between a position at whichthe opening of the metal pipe is width adjusted and a position at whichthe width adjusted opening portion of the metal pipe is welded, based ona thickness of the metal pipe; and setting the welding rate based on thethickness of the metal pipe and the set distance between the position atwhich the opening of the metal pipe is width adjusted and the positionat which the width adjusted opening portion of the pipe is welded.
 8. Amethod according to claim 7, wherein the distance setting step comprisessetting the distance between the position at which the opening of themetal pipe is width adjusted and the position at which the widthadjusted opening is welded to a range between 3 mm and 15 mm.
 9. Amethod according to claim 6, wherein the welding step comprisesirradiating the width adjusted opening portion of the metal pipe with alaser beam having a predetermined focal shift amount such that the laserbeam forms a focal point inside the width adjusted opening.
 10. A methodaccording to claim 9, wherein the welding step comprises:setting amaximum focal shift amount of the laser beam based on a minimum rearweld bead width; setting a minimum focal shift amount of the laser beambased on a maximum rear weld bead width; setting a welding rate inaccordance with the set maximum and minimum focal shift amounts; andirradiating the width adjusted opening portion of the metal pipe withthe laser beam within a range of the maximum and minimum focal shiftamounts.
 11. A method according to claim 7, wherein the optical fiberintroducing step comprises:inserting an optical fiber introducing andprotecting tube through the opening in the metal pipe to extendtherethrough at least to a welding position of said welding means wherewelding heat is generated; and introducing the optical fiber or theoptical fiber bundle into the metal pipe through said optical fiberintroducing and protecting tube.
 12. An apparatus for manufacturing anoptical fiber cable covered with a metal pipe, comprising:forming meansfor forming a metal strip into a metal pipe having a slit type openingby abutting two sides of the metal strip; opening width adjusting means,arranged downstream of said forming means, for adjusting a width of theopening to a predetermined size; welding means, having means forirradiating the metal pipe at the width adjusted opening with a laserbeam, for forming a sealed metal pipe by welding the abutting two sidesin the vicinity of the width adjusted opening; and optical fiberintroducing means for introducing an optical fiber or an optical fiberbundle into the sealed metal pipe; wherein said opening width adjustingmeans includes means for adjusting the width of the opening to thepredetermined size in accordance with at least one of a diameter,thickness and composition of the metal strip and in accordance with atleast one of a welding rate, laser beam power and laser beam focus shiftamount of said welding means; wherein said opening width adjusting meanscomprises squeeze shoe means, having an inner circumferential surface,for squeezing the metal pipe as the metal pipe passes therethrough, saidinner circumferential surface having a shape conforming to an outercircumferential surface of the metal pipe; wherein said squeeze shoemeans is provided at a distance of from 3 mm to 15 mm from a weldingposition of said welding means; wherein said apparatus further comprisesmeans for adjusting the distance from the welding position of saidwelding means at which said squeeze shoe means is provided; and whereinsaid squeeze shoe means comprises:an upper squeeze shoe and a lowersqueeze shoe; urging means for urging said lower squeeze shoe toward themetal pipe; and urging force adjusting means for adjusting an urgingforce of said urging means.